Display Cardboard Two Piece Package With Periphery Sealed Edges

ABSTRACT

A display two-piece cardboard package includes a first cardboard sheet having a top panel with a cut-out attached to a solid bottom panel of similar size. The top panel and the bottom panel overlay each other to form a common edge. A second cardboard sheet includes a second top panel and side panels that fold into a shell to enclose the product, the side panels having protruding tabs. The shell is inserted into the cut-out, and the first top panel folded over the bottom panel to form the package, with the protruding tabs sandwiched between the top and bottom panels. An adhesive is added to seal the common edges with the product inside, and optionally the edges may be crushed.

This application claims the benefit of the priority filing date of provisional application no. 61/638,171, filed on Apr. 25, 2012.

BACKGROUND

Blister packaging for small electronics goods is well known. One type of such display packaging consists of a pair of corrugated cardboard sheets joined together with a clear PVC plastic insert to show the product, and is popular with manufacturers and consumers. Consumers can see the product when contemplating a purchase, and for manufacturers the double cardboard layer package is rugged for protecting the product during shipping, and the sealed edges provide tamper resistance. See, for example, Nazari, U.S. Pat. No. 7,726,480.

There are environmental concerns with this popular type of packaging, however, as the cardboard and plastic portions are individually recyclable but must be separated for recycling. Even if designed to be separable, many consumers fail to make the effort. This is because the packaging is typically difficult to open and consumers resort to using a knife or scissors to cut the plastic portion and extract the product, leaving the plastic and cardboard together upon disposal. Accordingly, a better package is needed for displaying the product in a tamperproof fashion, and that is environmentally friendly as well as inexpensive to make.

Another issue with blister packaging for consumer products, having two sheets of corrugated cardboard and a clear plastic container sandwiched between them, is that this type of conventional packaging uses hot melt glue typically applied by hand and difficult to control due to the drying time and placement of the glue. Also, the corrugated sheets of the cardboard are visible on the side edges of the finished packaging which is aesthetically unappealing.

Other conventional blister packaging uses one sheet of corrugated cardboard and one or two flat sheet of paper. adhered together by adhesive. Since only one cardboard sheet is used, this type of packaging sometimes lacks sufficient structural strength when multiple display packs are stood on their sides in a container. When the weight of the top package is supported directly by the packs in the bottom bundle, they must have sufficient structural strength and rigidity to prevent them from bending.

SUMMARY

A two-piece package for displaying a product includes a first sheet having a top panel with a cut-out attached to a bottom panel. The top panel and bottom panel are sized to have a common peripheral edge when folded together. A second sheet includes a front panel bearing an image of the product on one side. The second sheet is foldable into a shell having a rear opening sized to receive the product, and includes protruding tabs.

The package is configured such that when the shell is inserted through the cut-out and the first sheet folded together, the tabs are sandwiched by the top panel and the bottom panel. To seal the package, an adhesive is applied between the first sheet and the second sheet along the common peripheral edge. The adhesive may also extend inward of the common peripheral edge as desired. In other embodiments, the tabs may extend into the common peripheral edge, and adhesive may be applied on the tabs as well. Also the common peripheral edge is preferably crushed around a majority of its perimeter to add strength and resiliency, and provide an attractive edge to the package.

The first sheet and the second sheet can each preferably comprise a printed side and a blank side, to make production easy and inexpensive. The first sheet and the second sheet may also be made of corrugated cardboard. Whether corrugated cardboard or another similar crushable material is used, the crushed area can extend inward of the common peripheral edge by approximately one half inch. Additionally, the first sheet and the second sheet may also have corresponding slots for forming a handle for hanging and carrying once the package is assembled.

To make the package, an image of a product is placed on one side of the sheet forming the shell, which will typically have a blank opposing side. The first sheet, once folded into a shell is placed through a cut-out portion of the folding sheet having the cut-out. When the shell is placed through the cut-out, the protruding tabs engage the cut-out. The sheet having the cut out is then folded over to cover the open side of the shell and enclose the protruding tabs, an adhesive is applied around the peripheral edge of folded sheet and the edge preferably crushed. The folded sheets may also include complimentary slots for forming a handle.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 a is a plan view of the printed side of a first cardboard sheet.

FIG. 1 b is a plan view of the printed side of a second cardboard sheet.

FIG. 2 a is a perspective view of the blank side of a first cardboard sheet.

FIG. 2 b is a perspective view of the blank side of a partially folded second cardboard sheet.

FIG. 3 is a perspective view of a folded second cardboard sheet prior to insertion into the blank side of a first cardboard sheet.

FIG. 4 is a perspective view of the printed side of a folded second cardboard sheet in position on the blank side of a first cardboard sheet.

FIG. 5 is a perspective view of a package with a folded second cardboard sheet incorporated into a folded first cardboard sheet.

FIG. 6 is a cut-away view of a folded second cardboard sheet incorporated into a folded first cardboard sheet.

REFERENCE NUMBERS

-   10. Package -   12. Crushed Area -   14. Periphery -   16. Handle -   100. First Sheet -   102. Top Panel -   104. Bottom Panel -   106. Cut-out -   108. Printed Side -   110. Indicia -   112. Blank Side -   114. Slots -   200. Second Sheet -   202. Printed Side -   204. Blank Side -   206. Front Panel -   208. First Side Panel -   210. Second Side Panel -   212. Third Side Panel -   214. Fourth Side Panel -   216. Tabs -   218. Side Flaps -   220. Shell

DESCRIPTION

Fig. IA shows in plan view a flat pattern of the printed side 108 of a first cardboard sheet 100. The first cardboard sheet 100 includes a top panel 102 and a bottom panel 104 for overlaying each other to form a common periphery. The top panel 102 comprises a cut-out 106. On the printed side 108, indicia 110, such as a product image, description, brand name and/or trademark, among others are preferably included. Only the printed side 108 and indicia 110 will be visible to purchasers when the first cardboard sheet 100 is folded. The first cardboard sheet 100 may also include slots 114 which form an integrated handle (not shown) when the first cardboard sheet 100 is folded prior to use.

FIG. 1B shows in plan view the flat pattern of the printed side 202 of a second cardboard sheet 200. The second cardboard sheet 200 includes a front panel 206 and four side panels 208, 210, 212 and 214, referred to a first through fourth side panels, respectively. Each of the side panels 208, 210, 212 and 214 include tabs 216, further characterized as outboard tabs 216 affixed to the side panels 208, 210. 212 and 214 distally from the front panel 206. The side panels 208, 210, 212 and 214 also include side flaps 218, used to connect the side panels 208, 210, 212 and 214 when the second cardboard sheet 200 is folded. In various embodiments, the side flaps 218 may be included on various combinations of the side panels 208, 210, 212 and 214.

FIG. 2A shows in perspective view the blank side 112 of the first cardboard sheet 100. The blank side 112 is preferably not visible when the top panel 102 is folded over the bottom panel 104, and therefore lacks any indicia. Also visible on the blank side 112 are the cut-out 106 and slots 114. FIG. 2B shows in perspective view the blank side 204 of the second cardboard sheet 200. In this view the front panel 206 is inward of the side panels 208, 210, 212 and 214, and the tabs 216, and side flaps 218 are visible in a partially folded configuration.

FIG. 3 shows a perspective view of the second cardboard sheet 200 folded into a shell 220, and placed in position to be incorporated into the first cardboard sheet 100. With the first cardboard sheet 100 in an unfolded configuration, the printed side 202 of the second cardboard sheet 200 including the top panel 204 (not shown) and the side panels 208, 210, 212 and 214 will be visible through the cut-out 106 when assembled. The tabs 216 remain on the blank side 112 of the first cardboard sheet 100, and the side flaps 218 remain on the blank side 204 of the second cardboard sheet 200 connecting the side panels 208, 210, 212 and 214 together. The top panel 102 is then folded over the bottom panel 104.

FIG. 4 shows another perspective view of the folded second cardboard sheet 200 when incorporated into the first cardboard sheet 100. In this view the position of the tabs 216 on the second cardboard sheet 200 prior to folding the top panel 102 over the bottom panel 104 is shown. Once the first cardboard sheet 100 is folded, the printed side 202 of the front panel 206 and side panels 208, 210, 212 and 214 of the second cardboard sheet 200 will be visible.

FIG. 5 shows a perspective view of the package 10 in an assembled state. In this view, the first cardboard sheet 100 has been folded together such that only the printed side 108 of the top panel 102 and printed side (not shown) of the bottom panel 104 are visible. The second cardboard sheet 200 is folded and extending through the cut-out 106, and the slots 114 form an integrated handle 16. Once the first cardboard sheet 100 is folded, only the printed side 202 of the front panel 206 and side panels 208, 210, 212 and 214 are visible. The tabs 216 (not shown) are sandwiched between the top panel 102 and bottom panel 104.

FIG. 6 shows a partial cut away side view of the package 10. When the package 10 is assembled, the folded first cardboard sheet 100 sandwiches the tabs 216, holding the second cardboard sheet 200 in place relative to the first cardboard sheet 100. To facilitate a secure union of the first cardboard sheet 100 and second cardboard sheet 200 the package 10 includes a crushed area 12 at its periphery 14. The crushed area 12 may also incorporate glue or other adhesives to form a secure package 10. It is contemplated a variety of seals may be used, i.e., heat seal, cold seal, glue, etc.

Ideally, any adhesive will be strong enough so the package 10 will stay together in transit, when stacked and while hanging on display, but weak enough so the package 10 can be opened by a consumer. Although, as mentioned above, it is believed many consumers do not open these types of packages as designed, the package 10 being made entirely of cardboard is recyclable without separation. With the indicia 110, such as a photograph of the product (not shown) printed on the package 10, customers can see what they're buying before a purchase occurs.

The foregoing description of the preferred embodiment 10 of the invention is sufficient in detail to enable one skilled in the art to make and use the invention. It is understood, however, that the detail of the preferred embodiment presented is not intended to limit the scope of the invention, in as much as equivalents thereof and other modifications which come within the scope of the invention as defined by the claims will become apparent to those skilled in the art upon reading this specification. For example, the package 10 may be formed by inserting the folded second cardboard sheet 200 through the cut-out 106 before folding the top panel 102 over the bottom panel 104, or may be formed by seating the folded cardboard sheet 200 on the bottom panel 104 before folding over the top panel. Also, the first cardboard sheet may not be contiguous, but may comprise a separate top panel 102 and bottom panel 104 separately brought together. obviating the need for folding the first cardboard sheet 100. 

What is claimed is:
 1. A package for displaying a product comprising: a first sheet having a top panel with a cut-out and foldable to create an underlying bottom panel; the top and bottom panels having a common peripheral edge around a majority of the package; a second sheet having a front panel bearing an image of the product on one side and being blank, and foldable into a shell having a rear opening sized to receive the product; the second sheet further having tabs connected to the shell, the package configured such that when the shell is inserted through the cut-out the tabs are sandwiched between the top panel and the bottom panel; and wherein the common peripheral edge is adhered together around the majority of the package.
 2. The package of claim 1, wherein the common peripheral edge is crushed around the majority of the package.
 3. The package of claim 2 wherein the adhesive extends inward of the common peripheral edge.
 4. The package of claim 1 wherein the tabs extend into the common peripheral edge.
 5. The package of claim 1 wherein the first sheet and the second sheet each have a printed side and a blank side.
 6. The package of claim I wherein the first sheet and the second sheet are made of corrugated cardboard.
 7. The package of claim I wherein the first sheet and the second sheet comprise corresponding slots for forming a handle.
 8. A cardboard display package for a product comprising a first cardboard sheet including a top panel having a cut-out and a bottom panel, wherein the top panel and the bottom panel lay back-to-back to each other to form a common peripheral edge; a second cardboard sheet including a front panel connected to side panels, each having outboard tabs; and wherein the side panels and front panel are folded to form a shell sized to receive the product and inserted into the cut-out, the outboard tabs are held between the top panel and bottom panel, and the top and bottom panels are adhered together and crushed at the common peripheral edge.
 9. A method of forming a cardboard package for holding a product comprising the steps of: applying an image of the product to one side of a first sheet; forming the first sheet into a shell sized to receive the product and having a protruding tab; placing the shell through a cut-out portion of a second sheet; inserting the protruding tab proximate a peripheral edge of the second sheet; folding the second sheet to sandwich the protruding tab and form a common peripheral edge with the first sheet; inserting the product into the shell; and applying an adhesive proximate the common peripheral edge to seal the product inside the package.
 10. The method of claim 9 further comprising the step of crushing the common peripheral edge.
 11. The method of claim 9 further including the step of providing complimentary slots in the second folding sheet to form a handle after folding. 